JP3095281B2 - Multi-product line production support system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a line production support system and a line production system in a factory that continuously produces a large number of products of a plurality of types, such as industrial machines and household appliances.

[0002]

2. Description of the Related Art At a predetermined time interval by a transfer device, a new work (object to be processed or assembled by a work equipment (processing or assembling apparatus or worker), which is a part or a final assembly). Is called a line production system in which a plurality of work elements (meaning each one of processing or assembly processes) are applied to a plurality of work facilities provided in the conveying direction on the work to which the work is fed. .

[0003] In this system, when a large number of works of the same model are continuously produced, the efficiency (operating rate) of work equipment and the workability of workers can be maintained extremely high.

However, when a plurality of types of workpieces having a short tact time (for example, about 20 seconds) are produced by the line production method, the work elements (work contents) and the work element time of the workpieces for each model are reduced. Due to the difference, it is necessary to change the work equipment, set up work, change jigs and tools, change the transfer time interval, etc. along with the model change, so it is difficult to maintain high equipment operation rate and workability Becomes

[0005] As a conventional technique for solving such a problem when a plurality of types of works are produced on a line, there is a method of producing all types of works by a single line (single line). As described in Japanese Patent Application Laid-Open No. 55-106756, a plurality of partial lines composed of equipment for exclusively applying work elements of only the same type of work are provided in parallel, and these plurality of provided lines are connected in series. There is a method of connecting and producing. Regardless of the method, a large number of workpieces are produced continuously for each same model. In a system that produces multiple types of work on a single line,
It is necessary to change the transport time of the work in each part of the line in a complicated manner every time the model is switched. However, when the transport time interval in each part of a single line changes with the change of the model, a work stagnation area or a vacant area occurs on the line, and the work efficiency of the entire line is significantly reduced. is there.

[0006] In a system in which a plurality of juxtaposed lines are connected in series, at least two main feeders for feeding and conveying the work are installed in parallel, and a number of tributary conveyors are juxtaposed in parallel. The main supply transport device is connected to each other, and the means for varying the transport speed of the work for each of the tributary transport devices is provided. When the production amount of each model fluctuates, it is necessary to change the configuration of the line equipment such as the number of tributary transfer devices and the speed of the transfer device, and there is a disadvantage that the management of the transfer devices is complicated.

[0007]

In the above-described conventional method, when a plurality of models are produced on a single line, a change in work equipment, setup work, a change in a transfer time interval, etc.
It is difficult to solve the problem of fluctuation of the total value (work load amount) of the work element times in each work facility.

According to the present invention, a plurality of types of work are sent by a transfer device, and a series (many) of work elements are applied to the work by a plurality of work facilities arranged in a line along the transfer direction of the transfer device. An object of the present invention is to provide a line production support system that enables a plurality of types of work to be produced in a given time on a production line.

[0009]

In order to achieve the above object, in a line production support system according to the present invention, a plurality of types of work are transported by a transport device and installed along the transport direction of the transport device. a plurality of work line production support system for operational support of the production line is subjected to a series of work elements work product by equipment, and classifiers
Work elements of multiple types of work to be sent to the line.
And / or information on work equipment
Input means for receiving the information, at least one of the information as a classification index, a classification means for classifying the plurality of types of work products into groups, the work of each group,
Knitting means for mixing according to the total production number of the work in each group and knitting into a production unit (mixed lot) consisting of a fixed number ;
For the work elements whose precedence order is specified in
After integrating overlapping work elements,
The execution order of each work element is maintained while maintaining the precedence order relationship.
An order integrating means for determining, a determining means for determining the production order, and an output means for outputting the obtained production order, wherein the input means accepts a change in the displayed classification result. is there.

[0010]

The input means transmits the classification index to the line.
Information on the work elements of multiple types of work
At least one of the information on the work equipment is received .

[0011] The above-mentioned classifying means includes information on work elements (type of work element,
Information on work equipment (type of specific work equipment among work equipment, type of specific jig or tool among jigs or tools (tool) used as auxiliary equipment of work equipment, etc.) ) Are classified into groups of a number smaller than the number of varieties of the work products as a classification index. As a result, the work belonging to each group includes the type of the work element to be applied or the total value of the work element time, that is, the work time required to produce one work, the work equipment to be used, or the work equipment. Jigs and tools used as auxiliary equipment will be similar. Therefore, when the work belonging to each group is produced on a single line, even if the work of a different model is continuously input, the change in the work content due to the change of the model is extremely small.

The knitting means mixes the work pieces of each group classified in this way in accordance with the total number of work pieces in each group, and forms a plurality of production units (mixed lots) of a fixed number. Organize. As a result, the work equipment, jigs and tools, the types of work elements for each mixed lot, and the size of the work element time in each work equipment become equal. This eliminates the need for setup work for work equipment and replacement of jigs and tools, and produces multiple types of work in a given period by repeatedly producing a plurality of types of work at a frequency corresponding to the production ratio. be able to.

[0013] The order integration means may be any of the above groups.
Work that prescribes the precedence order within the group.
After integrating the duplicate work elements into the business element group,
While maintaining the precedence order within the above group,
Determine the execution order of business elements .

[0014] The determining means determines a production order for the organized production units.

The order display means displays the production order thus determined.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of a line production support system according to the present invention is shown in FIGS. 1, 2, 3, 4, 8, 9, 10, 11, 12,.
13, 14, 15, and 16 will be described.

In FIG. 8, P is a work to be produced, and these are three groups (these are referred to as model A, model B, and model C) by a grouping method described below. To be decided). Assume that a total of 36 products are planned, including 18 models A, 12 models B, and 6 models C.

The configuration of the line production support system will be described.

As shown in FIG. 1, the system comprises an input means 2, a classification means 3, a classification display means 4, a classification change means 5, a knitting means 6, a multiplication means 7, a distribution means 8, ,
Distribution display means 9, distribution change means 10, and determination means 11
, An order display means 12, an order change means 13, and an output means 16. The determining means 11 comprises:
And order determining means 15.

FIG. 9 shows an internal configuration of hardware for realizing the present system.

This system comprises a keyboard 2 as input means 2, a display device 18 as output means 16, a printer 1
7 and an external storage device 19 and the main body 1. The main body 1 has a central processing unit (CPU) 20, a main memory 21 for storing programs and data, and interfaces 22 and 23. CPU 20 and main memory 2
1 and the interfaces 22 and 23 correspond to the classifying means 3, the classifying and displaying means 4, the classifying means 5, the knitting means 6, the integrating means 7, the distributing means 8, and the distributing and displaying means 9 shown in FIG. The functions of the distribution changing unit 10, the determining unit 11, the order displaying unit 12, the order changing unit 13, the calculating unit 14, and the order determining unit 15 are executed.

The line production support system operates according to the flow shown in FIG.

In step ST20, the input means 2 receives information on at least one of the work element and the work equipment. In step ST21, the classification means 3 classifies the data into groups. In step ST22, the classification display means 4
When displaying the classification result and selecting change, step ST2
In step 3, the classification changing means 5 changes the displayed classification result. In step ST24, the knitting means 6 knits into production units. In step ST25, the integrating means 7 obtains the sum of the work element times for each work facility. Step ST26
Then, the distribution means 8 distributes the work equipment. Step ST
At 27, when the distribution display means 9 displays the distribution result and selects a change, at step ST28, the distribution change means 9
Change the displayed distribution result. In step ST29, the determining means 11 determines a production order. Step ST30
When the order display means 12 displays the production order and selects a change, in step ST31, the order change means 13
Change the displayed production order. In step ST32, the output means 16 outputs the production order.

Next, a method of grouping the work P scheduled to be produced will be described with reference to FIGS. In FIG. 2, A1, B1,..., J1 are models of the work, e1, e2,.
Reference numerals 2,..., J20 denote jigs and tools used when each work element is applied. A circle at the intersection of a row representing each model of a work and a column representing a work element means that the work is subjected to the work element.

First, the method of dividing the ten types of models in step ST21 into several groups constituted by a group of similar models will be described in detail with reference to FIG. FIG. 3 is a flowchart of a process of exchanging rows and columns so as not to change the meaning of the intersection in FIG.
First, in FIG. 2, from the right of the column representing the work element name, the column of e20 is 2 ⁰ , the column of e19 is 2 ¹ , and so on.
Weights such as 2 ² , 2 ³ ,..., 2 ¹⁹ are calculated for each row, and the weight is calculated only for the circled portion, and the rows are rearranged from the top in descending order of the weight (step ST1). It is checked whether or not there is a change between the position of each row after the rearrangement and the position of each row before the rearrangement (step ST2). If there is no change, the exchange of rows and columns ends at this stage. If there is a change, the rows before sorting are updated to those sorted from the top in descending order of weight (step ST3). Against updated row, from below the line representing the model name, line 2 ⁰ model J for each row, the row of model C 2 ^1, Section 2 ^2, 2 ^3, ..., and so on 2 ⁹ Give weight. For each column, calculate the weight only for the places marked with a circle,
The columns are rearranged from the left in descending order of the weight (step ST4). It is checked whether or not there is a change between the position of each column after rearrangement and the position of each column before rearrangement (step ST5). If there is no change, the exchange of rows and columns ends at this stage. If there is a change, the column before rearrangement is updated to the column rearranged from the left in the descending order of the weight (step ST6), and the first process (step ST6) is performed.
Return to 1). By swapping the rows and columns in this way, the circles at the intersections are aggregated into an area surrounded by two sets of rows and columns as shown in FIG. When grouping is performed based on the result, the types of work A1 to perform the work from e1 to e7,
D1, E1, the types of work B1, F1, G1, H1, and I1 that perform the operations of e8 to e15, and e16 to e20
Are divided into three groups, such as models C1 and J1 of the work to be performed. Accordingly, the first group is referred to as model A, the second group is referred to as model B, and the third group is referred to as model C based on the result of grouping the work P to be produced.

Next, a method of displaying the above classification results on a screen and changing the classification results as needed will be described. FIG. 11 shows an example in which the classification result is displayed on a screen. In the drawing, the model group name is displayed at 30, the model names belonging to each model group are displayed at 31, and the names of all models to be classified are displayed at 32. When the user of this system desires to change the displayed classification result, he designates the group name (30) to be changed by using a keyboard or a mouse as an input device, and A model name determined to be unnecessary for the group is deleted or a new model name is selected from the target model name group (32) and designated.

If it is desired to change the classification according to the type of used jig / tool of each model, as shown in the example of FIG. 12, the used jig / tool of the model belonging to each model group and the jig / tool to be classified are provided. By displaying the groups, changes can be made in a similar manner.

Next, the grouped work P
A method of knitting into a plurality of production units will be described. The total production number of each group is 18 units of model A of the first group, 12 units of model B of the second group, and 6 units of model C of the third group, and is a ratio proportional to the total production number of each group. Is 3: 2: 1. Workpieces P grouped in this ratio are organized into production units having the minimum number. In this case, since the ratio of the model C is 1/6, the number of production units is a multiple of 6 or more, and here it is assumed to be 6 units. Since the grouped work pieces P are 36 in total, they are organized into six production units. The breakdown of the six works T for each production unit is three for model A, two for model B, and one for model C.

The work P of the production unit thus organized
A method of allocating the work elements related to the work equipment to the worker as the work equipment will be described with reference to FIG. e1, e2, ..., e2
0 is the name of the work element, and t1, t2,..., T20 are the times (work element times) required to execute each work element. For model A, e2 is a work element that cannot be performed unless e1 is completed, and e5 is a work element that cannot be performed if e2 is not completed. That is, the work elements related to the model A have an order of performing the work in the order of e1, e2, e5, e6, and e7. E8 and e for model B
There is an order in which the work is performed in the order of 9, e11, e12, and e13, and the model C also includes e16, e17, e18, and e1.
There is an order in which work is performed in the order of 9, e20. Models A, B,
When allocating the work elements of C to the workers of each process, the total sum of the time (work element time) required for the execution of all the work elements related to the work for each production unit is averaged for each process. Distribute. That is, in the first process, the sum of the work element times t1, t2, and t5 for the model A, the sum of the work element times t8 and t9 for the model B, and the work element time 0 ( T1 + t2 + t5 + t8 + t which is the sum of
9, and in the second step and the third step, similarly, t6
+ T7 + t11 + t12 + t13 + t16 + t17 + t
18 and t19 + t20. Next, the work elements are distributed by the distribution means so that these three sums are averaged. As this distribution means, “IE, Vol.
3, No. 14, 1971. (P137-P142)
A method such as "line balancing of a multi-model assembly line" may be used.

Next, a description will be given of a method of displaying the work elements allocated to each of the above steps and changing the work elements as necessary. FIG.
FIG. 3 shows an example in which the distribution result is displayed on the screen. At 40 in the figure, the work process name and the average value of the work element time allocated to each work process per model are shown, 41 is the work element name allocated to each work process, and 42 is the model-specific work element. At 43, a command menu for selecting a distribution result change function, which will be described next, is displayed for the total value for each time and production unit.

When the user of the present system desires to change the displayed distribution result (for example, in FIG. 14, the work time of each process is made uniform at about 190 seconds, In the case where the work load may be increased because the expert 3 is in charge of the skill, there is a case where the amount of work in the process 3 is increased by adding some element work from another process to the process 3). The above command menu is designated, and a distribution result change screen is started (FIG. 14). Using a keyboard and a mouse as input devices, a work element name (41) to be changed and a work step to be changed are designated (44). By specifying the change instruction completion menu (45),
Recalculate the work time and work distribution evaluation index (balance delay) after the change, and display the change result.

In FIG. 8, Q is input means for mixing at a ratio proportional to the total production number of each group and knitting into a plurality of production units (mixed lots) of a fixed number.

S1 is an operator in the first step, and S2
Is a worker of the second step, and S3 is a worker of the third step. The work area 1 is a range (work area) where the work of the worker S1 can be performed, and the work area 2 is a work area of the worker S1.
The work area 3 is a work area for the worker S3. R is a transport device that transports the work to each worker in each work area. T is a work for each production unit. j1 is a tool used by the worker S1 only for the model A, and j8 is a tool used by the worker S1 only for the model B. j6 is a jig used by the worker S2 only for the model A, j11 is a jig used by the worker S2 only for the model B, and j16 is a jig used by the worker S2 only for the model C. j19 is a tool used by the worker S3 only for the model C.

Here, when the work T for each production unit is sent to the work area 1 of the worker S1 in the first process at a fixed time interval by the transfer device R, the worker S1 Then, using the jig j8 of the model B, the work elements e1 and e8 of the models A and B are applied. Other work elements e
For 2, e5 and e9, a jig common to the models A and B is used, or the jig is used without using a jig. In this way, the work elements e1, e2, e5, e assigned to the worker S1 by the time the work items of the models A and B are transferred outside the work area 1 by the transfer device R in the work area 1.
8, e9 are performed.

Next, the work T for each production unit is sent to the work area 2 of the worker S2 in the second process at a constant time interval by the transfer device R. The worker S2 uses the jig j6 of the model A, the jig j11 of the model B, and the jig j16 of the model C to perform the work elements e6, e11, e1 of the models A, B, and C.
Apply 6. Other work elements e7, e12, e13, e
17 and e18 are performed using a tool common to the models A, B, and C, or without using any tool. In this manner, the work elements e6, e7, and e7 assigned to the worker S2 by the time the work items of the models A, B, and C are transported out of the work area 2 by the transport device R in the work area 2.
e11, e12, e13, e16, e17, e18 are performed.

Next, the work T for each production unit is sent to the work area 3 of the worker S3 in the third step at a constant time interval by the transfer device R. The worker S3 applies the model C work element e19 using the model C jig j19. The other work element e20 is applied using a common tool or without using a tool. Thus, in the work area 3, the model C is moved by the transfer device R to the work area 3.
The work elements e19 and e20 assigned to the worker S3 are performed before being transported outside.

As a result, the worker of each process has only to repeat the work element for each model assigned to the worker of each process by six production units. That is, a plurality of types of work can be repeatedly produced at a frequency corresponding to the production ratio, and the total of the work content and work element time for each production unit of the worker in each process is kept constant. Become.

Next, a method of displaying the production order determined by the determining means and changing it as necessary will be described. FIG. 15 shows an example in which the determined production order is displayed on a screen.
At 50 in the figure, the production order within the production unit is displayed.
When the user of the system desires to change the displayed production order (for example, the worker performing the work element YV-CASE-Z tape fixation * 3 in step-3 in FIG. 14 performs another work). Otherwise, the worker will have a lot of spare time after doing one long task, and if he wants to avoid this situation,
This change is made), and the changed production order is designated using a keyboard and a mouse as input devices (51).

FIG. 16 shows the result of the change.

Another embodiment of the present invention will be described with reference to FIGS.

There are work products A1, B1,..., J1 that are scheduled to be produced in the same manner as in FIG. 1, and the results of grouping them as shown in FIGS. Model A has 18 units, Model B has 12 units, and Model C has 6 units, totaling 36
Assume that production of a single product is planned.

The method of knitting the grouped works P into a plurality of production units is performed as described with reference to FIG.

In FIG. 5, Q is a device for arranging the production order of the work. j8 is the tool of model B used by S11, j1 is the tool of model A used by S12, j16 is S1
The jig tool of model C used by 3 and j11 is model B used by S14
J2 is a model A tool used in S15, and j6 is a model A tool used in S16. R is a transport device that transports the work to a range (work area) where each worker can work. T is a work for each production unit.

A method of arranging the production order of each work in the production unit will be described.

In the production unit, the number of models A, which are the first group of work, is 3, the number of models B, which is the second group of work, is 2, and the number of model C, which is the third group of work. Is one.

When the number ratio is obtained by the arithmetic means, the model A
Is 3/6, model B is 2/6, and model C is 1/6. Next, sorting is performed by the order determining means according to the number ratio. As a result, three units of model A in the production unit
If the model A is evenly distributed among the units, the model A is assigned so that one of two units appears in the production unit (A_A_A_).
Next, when two units of the model B in the production unit are evenly distributed among the six units of the production unit, the model B is assigned so that one in three units appears in the production unit (ABABA_). Model C
Are assigned in the same manner, the model C is assigned so that one out of six units appears in the production unit, and "ABABA
C ". In other words, the work order of each group is arranged so that the work order of each work appears at intervals of a frequency inversely proportional to the number of work items of each group in the production unit.

A method of arranging the workers who apply only the work elements related to the work in the same group of the production unit will be described.

Here, S11 and S14 are the operators who apply the work element only for model B, S12, S15 and S16 are the operators who apply the work element only for model A, and S13 is
He is a worker who applies work elements only for the model C.

As for the workers who apply only the work elements related to the first group work, the number of workers S12, S15, S16 which is equal to or less than the number (three) of the first group work in the production unit. Are arranged in a row along the transport direction of the transport device, and the number of workers (2 units) or less in the production unit (2 units) in the production unit, which applies only the work elements related to the second group of work. (2) workers S11 and S14 are arranged in a line along the transport direction of the transport device, and only those who apply only the work elements related to the third group of workpieces have the third group of workpieces in the production unit. The number (one) of workers S13 equal to or less than the number (one) is arranged in a line along the transport direction of the transport device. Therefore, workers in the first step are S11 and S12, workers in the second step are S13, S14, and S15, and workers in the third step are S16.

FIG. 6 shows a method of allocating work elements to each worker.
This will be described below.

It is assumed that the work is transported at a time interval of 15 seconds.

As described above, the model A appears at a frequency of one in two units in the production unit as described above. Therefore, for the workers S12, S15, and S16 who apply only the work elements of the model A, twice as long as 15 seconds. The task will be completed in 30 seconds. FIG.
In the line of model A, the work element e1 to be performed in the first process
Work elements e2 and e5 to be applied in the second step and work elements e6 and e7 to be applied in the third step.
Allocated to be close to seconds. The worker S12 has the work element e1, the worker S15 has the work elements e2 and e5,
The worker S16 applies work elements e6 and e7.

As described above, the model B appears at a frequency of one out of three units in the production unit, and therefore, for the workers S11 and S14 who apply only the work elements of the model B, the time is three times 15 seconds 45 You will be performing your work in seconds. In FIG. 6, the rows of the model B are work elements e8 and e9 performed in the first step and work elements e11, e12 and e13 performed in the second step.
The respective total times are distributed so as to be close to 45 seconds, and the worker S11 applies the work elements e8 and e9, and the worker S14 applies the work elements e11, e12 and e13.

As described above, the model C appears in the production unit at a frequency of one out of every six, so that for the worker S13 who applies only the work elements of the model C, it is six times 15 seconds 90
You will be performing your work in seconds. In FIG. 6, the line of the model C is the work elements e16, e17, e18,
e19 and e20, which are distributed so that the time is close to 90 seconds, and the worker S13 applies the work elements e16, e17, e18, e19, and e20.

A method for securing a work area for each worker will be described.

The work area 1 is a work area of the worker S11 (work area), the work area 2 is a work area of the worker S12, and the work area 3, the work area 4, the work area 5,
Similarly, the work area 6 includes workers S13, S14, S15, S
It is assumed that there are 16 work areas. The total production volume of each group in the production unit is model A, which is the work of the first group.
Are three, the model B, which is the work of the second group, is two, and the model C, which is the work of the third group, is one.

Here, an attempt is made to secure a work area for the worker S11. The worker S11 is a worker who applies only the work element related to the model B of the second group, and only needs to apply the work element only for the model B appearing in the work area of the worker S11. About 45 seconds. The work is transported at a time interval of 15 seconds, and the frequency of occurrence of the model B in the production unit is one out of three units. Therefore, when the worker S11 can perform the assigned work element, and secures a work area such that at least one model B, which is a work to be performed by the worker S11, appears in the work area of the worker S11 in FIG. This is the work area 1. When the work area 1 is secured in this way, the model B appears at an interval of one in three units in the production unit, and the worker S11 determines the assigned work element related to the model B that has appeared in the work area 1. If the operation is performed without any trouble, the worker S11 will not interfere with the work area of another worker.

Next, an attempt is made to secure a work area for the worker S12. The worker S12 is a worker who applies only the work elements related to the model A of the first group, and only needs to apply the work elements only for the model A appearing in the work area of the worker S12. Is about 30 seconds.
The work is transported at a time interval of 15 seconds, and the frequency of appearance of the model A in a production unit is one in two.
Therefore, when the worker S12 can perform the assigned work element and secures a work area such that at least one model A, which is a work to be performed by the worker S12, appears in the work area of the worker S12 as shown in FIG. It becomes work area 2. When the work area 2 is secured in this manner, the model A appears at a frequency of one in two in the production unit, and the worker S12 determines the assigned work element related to the model A that appears in the work area 2. If the operation is performed without any trouble, the worker S12 will not interfere with the work area of another worker.

Similarly, workers S13, S14, S15,
Also in S16, the work area 3, the work area 4, the work area 5, and the work area 6 are secured. That is, in the work area of the worker who applies only the work elements related to the work of the same group in the production unit, the work of the group to be performed by the worker always appears, and the work to be performed is performed by the transport device R. Thus, the assigned work element is carried out before being transported out of the work area.

As a result, it is possible to eliminate the interference of the work area due to the difference in the work time for each model group of the work, and to reduce the work loss due to the setup work due to the change of the work contents of the work equipment and the exchange of jigs and tools. And at the same time, the workability of each work facility can be improved.

In the above embodiment, a case where a worker or a work facility that applies only work elements related to work in the same group in a production unit moves, and the number of jigs and tools for each model group used for the work is limited. Another embodiment of the present invention will be described with reference to FIG.

Model A has 18 units, Model B has 12 units, Model C
Are planned to produce a total of 36 products.

The grouping is performed as described with reference to FIGS.

The method of knitting the grouped works P into a plurality of production units is performed as described with reference to FIG.

S32, S22,..., S32 are working facilities, S21, S27 are working facilities that apply only working elements of model C, and S22, S24, S26, S28, S30, S
32 is a work facility for performing only the work element of model A, S23,
S25, S29, and S31 are work facilities that apply only the work elements of model B. The work area i is the work equipment S21, S2
2,..., S32 are ranges (work areas) where a certain work element can be applied. j41 and j47 are jigs and tools used when performing a certain work of the model C in the work area i.
j44, j46, j48, j50, j52 are the work areas i
J4 used when performing a work with model A in j4
Reference numerals 3, j45, j49, and j51 denote jigs and tools used when performing a work with a model B in the work area i.

R1 is a transfer device for sending a work to the work area i, and R2 is a transfer device for transferring the work performed in the work area i to another work area.

Reference numeral V denotes a transfer device for transferring the work conveyed at a certain time interval by R1 together with the work equipment and the jig in the direction of the arrow.

U1 is a mounting device for moving the work carried by R1 to V and attaching it to a jig. U2 is a moving device that removes the work conveyed by V from the jig and moves it to R2.

Here, the work is transferred to the work area i at a time interval of 15 seconds by the transfer device R1.
It is assumed that the total of the respective working elements performed in S2,..., S32 is 180 seconds.

Next, the operation will be described.

It is assumed that the conveying device V is rotated, the work equipment S21 is in a state where the jig j41 work is not mounted, and the position thereof is between U1 and U2. The other work equipment S22, S23,..., S32 is being rotated by the transfer device V while performing the assigned work elements. Here, only the operation of the model C is performed S21
And j41 are transported to U1. At the same time, S32 is j
52, the model A and S32 and j52 for performing the work are performed by the transfer apparatus V to U2. j4
Reference numeral 1 denotes a state in which the model C as a work is removed, and U1 moves the model C transported by the transport device R1 to the transport device V and attaches it to the jig j1. At the same time, U2 removes model A from j52 and moves it to transport device R2. During these operations, other work equipment S22, S23, S24, S25, S26, S2
7, S28, S29, S30, and S31 provide work elements assigned to each work facility on the transport device V. U
When the work of 1, U2 is completed, S32 is transferred by the transfer device V in a state where the work is not attached,
S31 and j51 perform all assigned work elements before being transported to U2, and other work equipment also applies the assigned work elements. Next, S32 is U1
When S31 is transported to U2, U1
Moves the model A transported by R1 to the transport device V and attaches it to j52. At the same time, the model B is removed from j51 by U2 and moved to R2. Thereafter, these operations will be repeated.

When jigs and tools for each model group are required in a line facility as shown in FIG. 7, the production units must be knitted in consideration of the number of jigs and tools possessed by each model group.
A method of mixing the work pieces of each group to form a plurality of production units (mixed lots) of a fixed number will be described.

In FIG. 7, a model A for performing a certain operation
J42, j44, j46, j48,
j50 and j52, and the number of model A of the production unit is three. In addition, the number of jigs owned by model B is j
43, j45, j49, and j51, and the number of models B as production units is two. The number of jigs and tools owned by the model C is two, j41 and j47, and the number of the models C in the production unit is one. The number of each group in the production unit is less than the number of jigs and tools used by the work of each model group.
The work of each group is mixed according to the number of each group in the production unit to form a plurality of production units (mixed lots) of a fixed number.

As a result of knitting, model A, model B and model C
Is 3: 2: 1. As described above, when there is a limit to the number of jigs and tools, the production loss can be reduced by knitting the production units in consideration of the limitation.

The determination of the order for each model group in the production unit is performed as described with reference to FIG.

A method for installing work equipment on the transport device V will be described.

The work equipment for carrying out the work on the transport device V is arranged so as to be an integral multiple of the production unit and to correspond to the production order for each model group in the production unit. Therefore, 12 units, which are twice as many as the 6 production units, are placed on the transport device V.
The order of each model group within the production unit "ABABA
C ", the work equipment S21, S22,... Which applies only the work elements related to the work in the same group of the production unit.
S32 is arranged together with the jigs j41, j42, ..., j52. With such an arrangement, the exchange of jigs and tools due to the change of the work content can be reduced, the work conveyed to R by R1 can be sequentially attached to the jigs and work can be performed, and the work can be transferred to R2. Can be sent out without changing the production order.

A method for determining the time for one rotation of the transport device V will be described.

The time for one rotation of the transport device V is equal to or longer than the maximum value of the work element time performed by each work facility in the work area i, and is an integral multiple of the time interval at which the work is transported to the work area i by the transport device R1. So that Therefore, the transport device V only has to rotate once in 180 seconds, which is 12 times 15 seconds, which is the time interval in which the work is transported to the work area i by the transport device R1.

In such a line facility in which the work equipment rotates together with the transfer device, the area required for performing the work is (area for performing work of one work) × (in the work area. The number of work pieces on which work is performed) may be used.

Further, by sending the work for each production unit to the work equipment at regular time intervals, it is possible to reduce a setup work accompanying a change in the work content and a work loss due to the exchange of jigs and tools.

According to the present invention, a plurality of types of work are repeatedly produced at a frequency corresponding to the production ratio, and the total of the work contents and the work element time for each production unit in each work equipment is kept constant. Therefore, even when a plurality of models are produced on a single line, it is not necessary to change the transport time interval, and the fluctuation of the total value (work load amount) of the work element times in each work equipment is reduced.

Further, the work loss associated with the change of the work contents of the work equipment and the setup work and the exchange of jigs and tools can be reduced, and the workability of each work equipment can be improved. In production of a model, the change of work equipment and the setup work associated with the model change are reduced.

Further, since the interference of the work area due to the difference in the work time for each model group of the work can be reduced, the workability of each work equipment can be improved even when a plurality of models are produced by a single line.

Another embodiment of the present invention is shown in FIGS.
This will be described with reference to 9, 20, and 21.

This embodiment is different from the above embodiment in that an order integrating means, an integrating order displaying means, an integrating order changing means, a time displaying means and a time calculating means are added.

The order integrating means determines the work order of the work elements for a plurality of kinds from the work order (precedence order) of the work elements given for each kind. If there are work elements common to the work belonging to different groups, the work elements can be allocated to one work facility by the integrated precedent order determined in this way, and work can be leveled and efficient in the work facility. It can be expected that the food will be served properly and that the workers will be proficient.

The integrated order display means displays the integrated preceding order determined in this way.

The integration order changing means can change the displayed integration preceding order as needed.

The time calculation means calculates the start and end times of the work in each work facility of the work of a plurality of types sent to the line at the appearance frequency of the order determination means.

The calculation display means can display the time calculation result in a table and a graphic. As a result, the delay of the work with respect to the operation rate and the tact time for each work facility can be grasped. Further, the display order can be partially changed and the calculation can be performed again while displaying the calculation result as needed. The details will be described below.

As shown in FIG. 19, this system comprises an input means 2, a classification means 3, a classification display means 4, a classification change means 5, a knitting means 6, an order integration means 7, an integration order display Means 98, integration order changing means 99, and integrating means 8
Distribution means 11, distribution display means 9, distribution change means 10, determination means 11, sequence display means 12, sequence change means 13, time calculation means 91, calculation display means 92
And output means 16. The deciding unit 11 has a calculating unit 14 and an order deciding unit 15.

The present system has a keyboard as the input means 2, a display device and a printer as the output means 16, and further has an external storage device and a main body. The main body has a central processing unit (CPU), a main memory for storing programs and data, and an interface.

The CPU, main memory, and interface correspond to the classification means 3, the classification display means 4, the classification change means 5, the knitting means 6, the order integration means 7, and the integration order display means shown in FIG. 98, integration order changing means 99, integrating means 8, distribution means 11, distribution display means 9, distribution changing means 10, determining means 11, calculating means 14, order determining means 15, order display Means 12 and order changing means 1
3, the functions of the time calculation means 91 and the calculation display means 92 are executed.

The line production support system operates according to the flow shown in FIG.

In step ST20, the input means 2 receives information on at least one of the work element and the work equipment. In step ST21, the classification means 3 classifies the data into groups. In step ST22, the classification display means 4
When displaying the classification result and selecting change, step ST2
In step 3, the classification changing means 5 changes the displayed classification result. In step ST24, the knitting means 6 knits into production units.

In step ST25, the order integrating means 7 integrates the preceding order. In step ST126, the integration order display means 98 displays the integration precedence order. Step ST
At 127, the integration order changing means 99 changes the displayed integration preceding order.

In step ST128, the integrating means 8 obtains the sum of the work element times for each work facility. Step S
At T129, the distribution unit 11 distributes the work equipment. In step ST130, distribution display means 9 displays the distribution result. In step ST131, the distribution change unit 10
Change the displayed distribution result. In step ST132,
The determination means 11 determines a production order. Step ST1
At 33, the order display means 12 displays the production order. In step ST134, the order changing means 13 changes the displayed production order.

In step ST135, the time calculation means 91
Calculates the work start and end times of the work in each work facility. In step ST136, the calculation display means 9
2 displays a calculation result. It is possible to return to ST134 or ST131 as necessary.

In step ST137, the output means 16
Output the distribution result and production order.

Next, a method of simulating the production situation by the time calculating means 91 will be described.

According to the determined production order and distribution result, assuming that a plurality of types of work pieces of one mixed lot are to be transported on the line, the work start time and the work end time of each work equipment in each work equipment are determined. calculate. In FIG.
The example which displayed the time calculation result on the screen is shown. In FIG. 62, the delay with respect to the operation rate and the tact time of each process is 63
, The transition of the work in each work facility in the form of a Gantt chart is displayed, and the work start and end times of each work are displayed for the process designated by 62 in 64.

If the user of this system wishes to change the production order and the tact time based on the result, the change screen (60) is selected with the mouse, and the input is changed using the keyboard and mouse. Menu (6
Recalculation is possible by designating 5). If you want to change the allocation result, use the command menu (66)
To start the distribution result change screen (FIG. 14). These functions make it possible to search for optimal production conditions while referring to the calculation results.

FIG. 21 shows an embodiment of the present invention in which the work elements of the work belonging to different groups in the production unit have duplications in the above embodiment.

The work elements for the model A include Ea, Eb,
There is an order in which work is performed in the order of Ec, Ed, Ee1, Ef, Eg, and Eh. For model B, Ec, Ei, Ee2,
There is an order in which work is performed in the order of Ej1 and Ej2, and there is also an order in which work is performed in the order of Ek, Eb, Ei, Ee3, El, and Em for the model C.

When there is a work element common to the works belonging to different groups, by allocating those work elements to one work facility, work leveling, efficient serving, and worker You can expect mastery.

Therefore, the work elements of the models A, B, and C in FIG. 21 are integrated into one order (integrated precedence order). FIG.
Is a flowchart for explaining a method of integrating these preceding orders into one order.

The preceding order for each model is given as described above (step ST41). The order of reading is model A, C, B in descending order of the number of work elements (step ST4).
1). Each of the models A, C, and B is read one by one from above (step ST42). Then Ea, Ek, E
c, Eb, Eb, Ei, Ec, Ei, Ee2, Ed, E
e3, Ej1, Ee1, El, Ej2, Ef, Em, E
g, Eh are obtained (step ST4).
3). Here, it is checked whether or not the same or almost the same work element appears three or more times using several keywords such as used parts, processing or assembly contents included in the work element name. As a result, Eb, Ec, Ei, Ee
Are duplicated, the first one that appears is deleted, and the second and subsequent ones are deleted (step ST44). Then Ea, E
k, Ec, Eb, Ei, Ee, Ed, Ej1, El, E
An integrated precedence order j2, Ef, Em, Eg, Eh is obtained. However, since the order of Ec and Eb is inconsistent with the preceding order given to the model A, the order is changed. Similarly, the order of Eh and Ek and the order of Ee and Ed are also exchanged (step ST).
45). Since Ej1 and Ej2 are work elements using the same part, they are sorted and El and Ej2 are exchanged (step ST46).

According to the above procedure, Ea, Ek, E
b, Ec, Ei, Ed, Ee, Ej1, Ej2, El,
An integrated precedence order that satisfies the precedence order of each model Ef, Em, Eg, Eh can be obtained. Depending on the model,
When the order is inconsistent with Ea, Eb, Eb, Ea, the work elements Ea, Eb are collectively allocated to the same work equipment, so that the work can be prevented from running backward.

[0110]

According to the present invention, a plurality of types of work are sent by the transfer device, and a plurality of work facilities are arranged in a row along the transfer direction of the transfer device. It is possible to provide a line production management system that enables a plurality of types of work products to be produced in a certain period on a production line for applying work elements.

Further, by providing a function capable of directly changing production management information such as a combination of a plurality of types, a distribution of work elements, a production order, etc., it is possible to provide a system which can reflect a user's judgment at any time.

[Brief description of the drawings]

FIG. 1 is a block diagram of a line production support system according to the present invention.

FIG. 2 is an explanatory diagram showing the contents of work elements of 10 types of work in FIG. 8;

FIG. 3 is a flow chart when FIG. 2 is aggregated by assigning weights to each business and each column and classifying them into groups;

FIG. 4 is an explanatory diagram showing a result of equally assigning work elements to each process in FIG. 1;

FIG. 5 is a plan view showing another embodiment of the production line system according to the present invention.

FIG. 6 is an explanatory diagram showing a result of equally assigning work elements to each step in FIG. 5;

FIG. 7: Line equipment in which a transport device and work equipment move together,
It is a top view showing one example to which the line production system by the present invention is applied.

FIG. 8 is a plan view showing an embodiment of a production line system according to the present invention.

FIG. 9 is a hardware configuration diagram of a line production support system.

FIG. 10 is a flowchart showing the operation of the line production support system.

FIG. 11 is an explanatory diagram of a screen displaying a classification result of a production model group.

FIG. 12 is an explanatory diagram of a screen when a production model group is changed depending on a used tool.

FIG. 13 is an explanatory diagram of a screen displaying a result of allocating work elements to each process.

FIG. 14 is an explanatory diagram of a screen for changing a result of allocating work elements to each process.

FIG. 15 is an explanatory diagram of a screen displaying a production order.

FIG. 16 is an explanatory diagram of a screen for changing a production order.

FIG. 17 is a flowchart for determining an integrated preceding order of a plurality of models from a preceding order of each model.

FIG. 18 is an explanatory diagram of an example of a screen displaying a time calculation result.

FIG. 19 is a block diagram of another embodiment of the line production support system according to the present invention.

FIG. 20 is a flowchart showing an operation of the line production support system of another embodiment.

FIG. 21 is an explanatory diagram showing a preceding order of each model.

[Explanation of symbols]

P: work, A, B, ..., J: model, Q: loading device, R, R1, R2: transport device, V: transport device, U1
... Mounting device, U2 ... Moving device, T ... Production unit, S1
... S3, S11 to S16 ... workers, S21 to S32 ...
Work equipment, e1 to e20 ... work elements, j1 to j20,
j41 to j52 ... jig / tool name, Ta to Tj ... work element time.

Continued on the front page (72) Inventor Hirotaka Morita 292 Yoshida-cho, Totsuka-ku, Yokohama-shi, Kanagawa Prefecture Inside Hitachi, Ltd. Production Research Laboratory (72) Inventor Akira Kagoshima 292, Yoshida-cho, Totsuka-ku, Yokohama-shi, Kanagawa, Inc. Hitachi, Ltd. Yokohama Plant (72) Inventor, Tetsuo Kojima 800, Tomita, Ohira-cho, Shimotsuga-gun, Tochigi Prefecture Hitachi, Ltd. Tochigi Plant (56) References JP-A-4-75105 (JP, A) JP-A-4-4- 300149 (JP, A) JP-A-4-69137 (JP, A) JP-A-1-234142 (JP, A) JP-A-62-173155 (JP, A) JP-A-4-75836 (JP, A) (58) Fields surveyed (Int. Cl. ⁷ , DB name) G06F 17/60 B23Q 41/08 B65G 37/00 JICST file (JOIS)

Claims (10)

(57) [Claims] An operation support system for a production line in which a plurality of types of work are transported by a transport device and a series of work elements are applied to the work by a plurality of work facilities installed along the transport direction of the transport device. This is a line production support system that performs multiple types of work
Limited information on work elements and work equipment
Input means for accepting at least one of the pieces of information, classifying means for classifying the plurality of types of work products into groups using at least one of these pieces of information as a classification index, and Knitting means for knitting into a production unit (mixed lot) consisting of a certain number by mixing according to the total production number of the work products, and belonging to any of the above groups and leading in the group
For work elements whose order is specified,
After integrating the business elements,
Order that determines the execution order of each work element while maintaining the
Introducing line integrating means, determining means for determining a production order, and output means for outputting the obtained production order, wherein the input means accepts a change in the displayed classification result. Support system. 2. A line production facility set by the line production support system according to claim 1, wherein the facility for performing each work element is executed in accordance with the execution order of the work element determined by the sequence integration means. Line production equipment that is set up according to the method of transporting work. 3. A production line in which a plurality of types of work are transported by a transport device and a series of work elements are applied to the work by a plurality of work facilities installed along the transport direction of the transport device. This is a line production support system that performs multiple types of work
Limited information on work elements and work equipment
Input means for receiving at least one of the pieces of information, at least one of the pieces of information as a classification index, a classification means for classifying the plurality of types of work products into groups, and a classification display means for displaying a group classification result. A classification changing means for changing the classification result in accordance with the received classification result change instruction; and a fixed number of the work products of each group mixed with the total number of the work products of each group according to the total number of work products. Knitting means for knitting into production units (mixed lots); deciding means for deciding a production order; and output means for outputting the obtained production order. The input means is an instruction to change the displayed classification result. A line production support system characterized by accepting a request. 4. A production line in which a plurality of types of work are transported by a transport device and a series of work elements are applied to the work by a plurality of work facilities installed along the transport direction of the transport device. This is a line production support system that performs multiple types of work
Limited information on work elements and work equipment
Input means for accepting at least one of the pieces of information, classifying means for classifying the plurality of types of work products into groups using at least one of these pieces of information as a classification index, and Knitting means for knitting into a production unit (mixed lot) consisting of a certain number by mixing according to the total production number of work products, determining means for determining a production order, and order display means for displaying the determined production order And a sequence changing means for changing the production order in accordance with the received change order of the production order; and an output means for outputting the obtained production order. The input means includes the instruction to change the displayed production order. A line production support system characterized by accepting a request. 5. The operation support of a production line in which a plurality of types of work are transported by a transport device and a series of work elements are applied to the work by a plurality of work facilities installed along the transport direction of the transport device. This is a line production support system that performs multiple types of work
Limited information on work elements and work equipment
Input means for accepting at least one of the pieces of information, classifying means for classifying the plurality of types of work products into groups using at least one of these pieces of information as a classification index, and Knitting means for mixing according to the total production number of the work pieces and knitting them into production units (mixed lots) each consisting of a fixed number, and the time required for performing the work elements in the production units obtained by the knitting means (work Means for calculating the total sum of each work facility (element time), distribution means for averaging the sum total for each work facility and distributing to a plurality of work facilities, and distribution display means for displaying the distribution result, and the received distribution result In accordance with the change instruction, the distribution change means for changing the displayed distribution result, the determination means for determining the production order, and the output means for outputting the obtained production order, The determining means determines the production order in consideration of the distribution to the work equipment, and the input means receives an instruction to change the displayed distribution result. 6. The line raw material according to claim 1, 3, 4, or 5.
In the production support system, the determining means is a calculating means for calculating a ratio of the total number of products for each group
And order to appear on the line at a frequency proportional to the number ratio
Production support system characterized by having
M 7. The line production support system according to claim 6,
At the appearance frequency determined by the order determination means.
Of work to be sent to
Time calculating means for calculating the start and end times, calculation display means for displaying the calculation result, and means for changing the displayed production order; and the input means for changing the displayed production order. Accept
A line production support system characterized by: 8. The method according to claim 1, 3, 4, 5, 6, or 7.
In the line production support system, the knitting means includes a work piece in the obtained production unit.
Number of tools in each group or jigs and tools used by the work
Mix the work of each group with a small number of
To a certain number of production units (mixed lots)
Line production support characterized by the provision of means for knitting
system. 9. A plurality of types of workpieces are transported by the transport device.
Are installed along the transport direction of the transport device.
A line where a series of work elements are applied to work by industrial equipment
A production line according to claim 1, 3, 4, 5, 6, 7 or 8.
According to the production order obtained by the production support system,
The work for each production unit is transferred to the transfer device at regular time intervals.
By providing feeding means, it is possible to
It is characterized by producing industrial products according to the number of products produced
Multiple product line production system. 10. The work according to claim 9, wherein the work is electric equipment.
Production by the above-mentioned line production method.
Electrical equipment production method.